This guide is for those who enjoy working with their hands and have some experience with woodworking and design.
If you have access to a well-equipped workshop and a budget for quality materials, this project will be both rewarding and enjoyable.
Supplies and Tools You’ll Need
Before diving into the project, gather all the necessary tools and supplies. Here’s what I used:
Woodworking Equipment
- Woodworking bench
- Table saw
- Planer thicknesser
- Band saw
- Router (with tenon and hinge router bits)
- Electric orbital sander
Safety Equipment
- Safety glasses
- Ear protection
- Steel-capped boots
- High-strength disposable gloves
Hand Tools
- Cordless drill
- T-square ruler
- Clamps
- Chisel
- Fine-detail hammer (preferably Japanese woodworking style)
- Nail punch tool
Materials
- European beech wood or similar (dimensions outlined in steps below)
- Shoji paper (minimum 6m x 500mm)
- Shoji glue (200ml)
- Quality wood glue (200ml)
- Hardwax oil (300ml)
- Hinges and screws (brass, brushed effect)
- Sandpaper (120, 180, and 400 grit)
- Masking tape
- Floor protectors
Step 1: Evaluate Your Space
First, determine the dimensions of the room divider. This is critical to ensure stability and proper proportions. My design includes three panels, each measuring 1850mm high, 483mm wide, and 20mm thick. Adjust these measurements to fit your needs but maintain proportions for stability.
Step 2: Choose and Source Materials
Select your wood carefully. I chose European beech for its strength, ease of use, and warm color, but European ash is another excellent option for a lighter finish. Once you’ve decided, source your materials from a reputable supplier.
Step 3: Prepare the Wood for the Exterior Frame
- Use a planer to smooth the wood and ensure uniform thickness.
- Cut the following pieces to size:
- 6 pieces: 1850mm x 50mm x 20mm
- 3 pieces: 423mm x 100mm x 20mm
- 3 pieces: 423mm x 75mm x 20mm
Step 4: Create Mortise and Tenon Joints for the Exterior Frame
- Mark and cut 12 tenons on the short pieces using a bandsaw, then refine with a chisel.
- Use a router to create 12 mortises on the long pieces. Ensure the joints fit snugly.
Step 5: Assemble the Exterior Frames
- Dry-fit the pieces to ensure everything aligns.
- Apply wood glue to the joints, clamp the frame together, and let it dry for 24 hours.
Step 6: Prepare and Assemble the Interior Frames
- Plane and cut the wood for the interior frames:
- 18 pieces: 383mm x 20mm x 12mm
- 3 pieces: 1675mm x 20mm x 12mm
- Create half-lap joints by cutting half the wood’s thickness at designated points.
Step 7: Attach the Interior Frame to the Exterior Frame
- Secure the interior frame to the exterior frame using nails. Drill angled holes, then hammer and punch nails into place.
Step 8: Prepare the Hinges
- Mark hinge locations and use a router to create mortises for them.
- Drill screw holes and test-fit the hinges to ensure alignment.
Step 9: Apply a Protective Oil Finish
- Sand the frames with 120 and 180 grit sandpaper.
- Apply three coats of hardwax oil, lightly sanding with 400 grit between the second and third coats.
Step 10: Attach the Shoji Paper
- Lay the frame flat and carefully tape down the shoji paper.
- Apply glue in sections and attach the paper, smoothing it out as you go.
- Trim excess paper with a sharp knife.
Step 11: Add Wooden Borders to the Back
- Cut, plane, and sand wooden strips for the back borders.
- Glue these strips onto the frame, pressing them into place with weights.
Step 12: Final Assembly
- Reattach the hinges, aligning the panels for smooth folding.
- Add floor protectors to the base of each panel.
Tips for Success
- Research different styles of shoji paper to find a design that suits your space.
- Test your tools and techniques on scrap wood before working on the actual pieces.
- Ensure all joints are tight and aligned to maintain structural integrity.
Enjoy Your Handmade Shoji Screen
Once complete, your shoji screen will not only divide your space but also add a touch of timeless elegance. Its translucent panels will diffuse light beautifully, creating a serene ambiance in any room. Share your finished project with us—we’d love to see how you bring this design to life!
Project Via Instructables – Get the PDF Instructions here.
